220 Piston Pump Service Manual

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220 Piston Pump Service Manual | Manualzz

220 Piston Pump

Service Manual

Table of Contents

Part Identification .......................................................................................................................................................................................3

Exploded Assembly ....................................................................................................................................................................................4

Optional Assembly......................................................................................................................................................................................5

Typical Cross Section ..................................................................................................................................................................................6

Shaft, Drive and Key ...................................................................................................................................................................................7

End Cover S/A ............................................................................................................................................................................................8

Valve Plate ..................................................................................................................................................................................................9

Housing .................................................................................................................................................................................................... 10

Rotating Group ......................................................................................................................................................................................... 10

Swash Plate .............................................................................................................................................................................................. 10

Shaft Seal.................................................................................................................................................................................................. 10

Compensator ............................................................................................................................................................................................ 11

Plug Subassemblies ................................................................................................................................................................................. 11

Pump Repair .............................................................................................................................................................................................12

Inspection, Repair and Part Replacement .................................................................................................................................................16

Assembly ..................................................................................................................................................................................................19

Assembly Torque Values ...........................................................................................................................................................................22

2 EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014

Part Identification -

220 Series Pumps

Item

1

2

Part Number

See table 1

6028118-XXX

Quantity Description

1

AR

Shaft, Drive

Spacer, Bearing / Bearing Shim Kit 

3

4

5

6

See table 1

See Table 2

16026-610

See table 3

1

1

1

1

Key, Driveshaft

End Cover S/A

Roll Pin

Valve Plate

7 104166-156 1 O-Ring

8

9

10

See table 4

388153

02-335336

1

1

1

Housing

Bearing Assembly, Shaft (Front)

Bearing Assembly, Shaft (Rear)

15

16

17

18

11

12

13

14

6026924-001

114995-010

5992034-001

6026917-001

6026982-001

114977-035

16253-218

16077-032

1

4

1

1

2

2

1

1

19

20

21

22

See Table 8

107275-011

107275-017

114953-030

1

4

1

4

23

24

6030097-001

16103-312

1

1

25 16103-302 3

26 See table 9 3

Bearing, Swash Plate

Screw, Cap, Socket

Spring, Bias

Swash Plate

Rotating Group S/A

Screw, Cap (Housing / End cover)

Seal, Shaft, Fluorocarbon l

Ring, Retaining, Internal (Shaft Seal) l

Compensator S/A

O-Ring (Secondary Compensator / Housing) l

O-Ring (Compensator / Housing) l

Screw, Cap (Compensator Mounting)

Piston, Control

Plug, Fixed Volume Stop u

Plug

Plug (Bottom, Top and Side Case Drain Ports)

31

32

33

34

27

28

29

30

See table 9

See table 9

6026914-001

114995-010

5990203-001

54999158

104166-021

6024371-002

35

36

37

38

6027085-001

16026-406

6030096-350

692866

39 16133-12

40 937166

1

1

1

1

1

1

1

1

2

1

1

1

1

2

Plug (Vertical Case Drain Port)

Plug (Diagnostic Port)

Link, Feedback (Feedback Sensor Option)

Screw, Cap, Socket, Flat, Countersunk (Feedback Sensor Option)

Magnet Carrier (Feedback Sensor Option)

Adapter, Swash Sensor (Feed Sensor Option)

O-Ring (Adapter / Swash Sensor Assy) l (Feedback Sensor Option)

Feedback Sensor, Non-Contact (Feedback Sensor Option)

Screw, Cap S/A (Swash Sensor) (Feedback Sensor Option)

Pin, Roll (Feedback Link) (Feedback Sensor Option)

Screw, Cap u (Adjustable Maximum Stop Option)

Nut Sealing u (Adjustable Maximum Stop Option)

Tamper Proof Cap l Standard Seal Kit: 9900959-000

 Shaft bearing Shim Kit: 9900961-000

10

10

11

10

10

9

7

8

Page Number

7

18

5

5

11

11

11

11

5

5

5

5

5

5

5

5

5

EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014 3

Exploded Assembly -

220 Series Pump

Part Item Number

4 EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014

Optional Assembly

-

220 Series Pumps

Part Item Number

Feedback Sensor Option

Adjustable Maximum

Stop Option

24

EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014 5

Typical Cross Section

-

220 Series Pumps

Side View

6 EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014

Shaft, Drive and Key - Item 1 & 3

Table 1

Table 1 - Shaft, Drive and Key (Items 1 & 3)

Code Position

4,5,6 8,9

028 05

028

028

028

09

31

34

24,25

00

00

00

00

Key (Item 3)

24500-619

-

16246-516

-

Part Number

6026704-003

6026704-001

6026704-002

6026704-004

Description

Shaft, Drive, 22.2 Dia. Straight Key, 41 mm Ext.

Shaft, Drive, Input 13 Tooth 16/32, 41 mm Ext.

Shaft, Drive, 25.4 Dia. Straight Key, 46 mm Ext.

Shaft, Drive, Input 15 Tooth 16/32, 46 mm Ext.

220 Series Mobile Piston Pump

Drive Shaft

EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014 7

End Cover S/A - Item 4

Table 2

Table 2 - End Cover S/A (Item 4)

Code Position

4,5,6 7

028 L,R

028

028

028

028

028

L,R

L,R

L,R

L,R

L,R

10,11 13

AA 1

AB

AC

AD

AE

AF

1

2

2

1

1

24,25

00

00

00

00

00

00

Part Number

6026786-002

6026786-001

6026786-006

6026786-005

6026786-004

6026786-003

Description

End Cover S/A, Rear Port 28 cc (O-ring Port)

End Cover S/A, Side Port 28 cc (O-ring Port)

End Cover S/A, Rear Port 28 cc Metric

End Cover S/A, Side Port 28 cc Metric

End Cover S/A, Rear Port 28 cc (4 Bolt Flange Port)

End Cover S/A, Side Port 28 cc (4 Bolt Flange Port)

220 Series Mobile Piston Pump

End Cover views

Side Port

8 EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014

Rear Port

Valve Plate - Item 6

Table 3

Table 3 - Valve Plate (Item 6)

Code Position

4,5,6 7

028

028

R

L

Part Number

6029630-001

6029630-002

Description

Plate, Valve (RH 28 cc)

Plate, Valve (LH 28 cc)

220 Series Mobile Piston Pump

Valve Plate Identification

RH LH

EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014 9

Housing - Item 8

Rotating Groups - Item 15

Swash Plate - Item 14

Shaft Seal - Item 17

Tables 4, 5, 6 & 7

Table 4 - Housing (Item 8)

Code Position

8,9 12 27,28

05,09,31,34 A,B,G AB

05,09,31,34 A,B,E,G 00

05,09,31,34 C,D,F,H 00

Part Number Description

6026919-001 Housing (Feedback Sensor)

6026919-002 Housing

6026919-003 Housing Metric Drain Port

Table 5 - Rotating Group (Item 15)

Code Position

4,5,6

028

Part Number

6026982-001

Description

Rotating Group S/A (28 cc)

Table 6 - Swash Plate (Item 14)

Code Position

4,5,6

028

Part Number

6026917-001

220 Series Mobile Piston Pump

Swash Plate View

Table 7 - Shaft Seal (Item 17)

Code Position

4,5,6

1

Part Number

16253-218

220 Series Mobile Piston Pump

Shaft Seal View

Description

Swash Plate (28 cc)

Description

Seal, Shaft, Fluorocarbon

10 EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014

Compensator - Item 19

Plug Subassemblies - Item 26, 27 & 28

Table 8, 9

C

C

C

C

C

C

B

B

B

Table 8 - Compensator (Pump Controls) (Item 19)

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

Control

Code Code

14 15,16 Pressure Limit Setting

A 27 199.9-206.8 bar [2900-3000 lbf/in 2 ]

28

28

28

28

28

28

32

35

206.8-213.7 bar [3000-3100 lbf/in

206.8-213.7 bar [3000-3100 lbf/in

206.8-213.7 bar [3000-3100 lbf/in

206.8-213.7 bar [3000-3100 lbf/in

206.8-213.7 bar [3000-3100 lbf/in

206.8-213.7 bar [3000-3100 lbf/in

226.5-233.4 bar [3285-3385 lbf/in

241.3-248.2 bar [3500-3600 lbf/in

2

2

2

2

2

2

2

2

]

]

]

]

]

]

]

]

42

42

43

43

36

36

40

40

43

43

246.5-253.4 bar [3575-3675 lbf/in 2 ]

246.5-253.4 bar [3575-3675 lbf/in 2 ]

262.0-268.9 bar [3800-3900 lbf/in 2 ]

262.0-268.9 bar [3800-3900 lbf/in 2 ]

272.4-279.3 bar [3950-4050 lbf/in 2 ]

272.4-279.3 bar [3950-4050 lbf/in 2 ]

275.8-282.7 bar [4000-4100 lbf/in 2 ]

275.8-282.7 bar [4000-4100 lbf/in 2 ]

275.8-282.7 bar [4000-4100 lbf/in 2 ]

275.8-282.7 bar [4000-4100 lbf/in 2 ]

28

28

43

206.8-213.7 bar [3000-3100 lbf/in 2 ]

206.8-213.7 bar [3000-3100 lbf/in 2 ]

275.8-282.7 bar [4000-4100 lbf/in 2 ]

12 137.9-144.8 bar [2000-2100 lbf/in 2 ]

19 168.9-175.8 bar [2450-2550 lbf/in 2 ]

21 179.3-186.2 bar [2600-2700 lbf/in 2 ]

28

43

206.8-213.7 bar [3000-3100 lbf/in

275.8-282.7 bar [4000-4100 lbf/in

2

2

]

]

45 306.8-313.7 bar [4450-4550 lbf/in 2 ]

24

28

24

00

00

00

00

00

00

Code

17,18 Flow Setting

25 23.44-26.89 bar [340-390 lbf/in 2 ]

10 2 ]

14

14

23

12.41-15.17 bar [180-220 lbf/in

12.41-15.17 bar [180-220 lbf/in

23.10-25.17 bar [335-365 lbf/in

2

2

2

]

]

]

24

30

22.75-25.51 bar [330-370 lbf/in 2 ]

28.27-31.72 bar [410-460 lbf/in 2 ]

16 13.79-16.55 bar [200-240 lbf/in 2 ]

14 12.41-15.17 bar [180-220 lbf/in 2 ]

14 12.41-15.17 bar [180-220 lbf/in 2 ]

22 20.68-23.44 bar [300-340 lbf/in 2 ]

14 12.41-15.17 bar [180-220 lbf/in 2 ]

10 2 ]

10 2 ]

10 2 ]

14

14

12.41-15.17 bar [180-220 lbf/in 2 ]

12.41-15.17 bar [180-220 lbf/in 2 ]

16

24

13.79-16.55 bar [200-240 lbf/in 2 ]

22.75-25.51 bar [330-370 lbf/in 2 ]

22.75-25.51 bar [330-370 lbf/in 2 ]

26.20-28.96 bar [380-420 lbf/in 2 ]

22.75-25.51 bar [330-370 lbf/in 2 ]

No Flow Comp. Setting

No Flow Comp. Setting

No Flow Comp. Setting

No Flow Comp. Setting

No Flow Comp. Setting

No Flow Comp. Setting

00

0A

00

00

00

00

00

00

00

Code

21,22

00

00

00

00

00

0A

00

0A

00

00

0A

00

0A

00

0A

0A

00

00

00

Kit Number

9900512-003

9900512-013

9900512-022

9900512-026

9900512-001

9900512-032

9900512-017

9900512-002

9900512-028

9900512-014

9900512-031

9900512-005

9900512-027

9900512-007

9900512-006

9900512-010

9900512-015

9900512-008

9900512-018

9900512-012

9900512-019

9900512-011

9900512-021

9900512-023

9900512-029

9900512-016

9900512-009

9900512-004

Kit Contents

21

20

19

40

22 4x Torque 8.2±0.8 Nm

Table 9 - Plug Subassemblies (Items 26, 27 & 28)

Code Position

12

A,B,E,G

C,D,F

A,B,E

C,D,F

-

-

-

1

2

13

-

-

-

-

-

-

27,28

00,AB

00,AB

-

Part Number

16103-310

9237-005

16103-308

9237-004

16103-304

9237-002

Description

Plug (Bottom, Side and Top Case Drain) .875-14 UNF-2B Thd.

Plug (Bottom, Side and Top Case Drain) M22 X 1.5 Thd.

Plug (Vertical Case Drain) .750-16 UNF-2B Thd.

Plug (Vertical Case Drain) M18 X 1.5 Thd.

Plug (Diagnostic Ports) .4375-20 UNF-2B Thd.

Plug (Diagnostic Ports) M12 X 1.5 Thd.

EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014 11

Pump Repair

Cut Section

12 EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014

Pump Repair

Cut Section

1. Remove Control Piston Plug Assembly 2. Install Swash Plate Locator Tool Adjustment will take place in step 11.

3. Remove Compensator

4. Remove End Cover Mark the housing and end cover to ensure orientation. Remove the four cap screws that hold the end cover in place.

Note: The valve plate may stick to end cover. Use caution so valve plate does not fall off.

5. Remove O-ring Seal

6. Remove Valve Plate

7. Remove Bearing Race The bearing race is pressed in and will require the use of a sliding bearing removal hammer or similar tool to remove it.

8. Remove Bearing

EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014 13

Pump Repair

Cont.

9. Remove Housing O-rings 10. Install Swashplate retainer install the swash plate hold down tool and tighten the cap screw. This will prevent the swash plate from moving.

11. Swashplate adjustment locator with the hold down tool in place, tighten the adjustment screw so the control piston spring is compressed.

Note: This step is designed to force the swashplate to a neutral position to enable easy removal of the rotating group, and to retain the swashplate.

12. Install Shaft Retainer Tool and tighten the set screw while being careful not to damage shaft.

13. Remove rotating group

14. Remove shaft remove shaft retainer tool and lift out shaft. Use caution when moving shaft through shaft seal.

15. Remove Swashplate Locator 16. Remove Swashplate Retainer

14 EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014

Pump Repair

Cont.

17. Remove Control Piston

19. Remove Bias Spring

18. Remove Swashplate

20. Remove Bearing

21. Remove Cradle Bearing Screws Caution: Socket head cap screws are easily damaged during repair with improper tool.

22. Remove Cradle Bearings Note: The cradle bearings are asymmetrical.

Note: Proper orientation shown in picture.

23. Remove Front Bearing Race 24. Remove Shaft Seal With the seal retaining ring removed use a punch or similar tool to knock out the shaft seal.

EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014 15

Inspection, Repair and

Part Replacement

Inspection

Inspection

Before inspection of parts, clean with a solvent that is compatible with system fluid.

Piston Block

Rotating Group Parts

1. Inspect cylinder block face for wear, scratches, and/or erosion. If cylinder block condition is questionable, replace the entire rotating group.

2. Remove the pistons, shoe retainer, and pivot from piston block. The piston block assembly doesn’t need to be disassembled unless the internal pins or spring are damaged.

3. Check each cylinder block bore for excessive wear. Use the piston and shoe S/A for this purpose. The pistons should be a very close fit and slide in and out of the cylinder block bores. NO BINDING CAN BE TOLERATED. If binding occurs, clean the cylinder block and pistons. Lubricate the cylinder block bores with clean fluid and try again. Even minor contamination of the fluid may cause a piston to freeze up in a cylinder bore.

4. Inspect each of the nine piston and shoe S/A for a maximum end play of 0.005 inch between the piston and shoe.

Also check the face dimension of each shoe. The face dimension must be within 0.001 inch.

5. Inspect shoe retainer and pivot for wear and/or scratches.

If condition is questionable, replace entire rotating group.

Pivot

Note: Do not lap the face of piston block assembly.

Piston S/A Tolerances This dimension must be maintained on all nine shoes within 0.001 inch.

± 0.001”

Between Piston

Shoes (9)

Shoe Piston

Shoe face rides on swash plate. Shoe must swivel smoothly on ball.

End play must not exceed

0.005 inch.

Movement up to 0.005”

Shoe

Retainer

Piston (9) and Shoe

S/A

16 EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014

Inspection, Repair and

Part Replacement

End Cover &

Associated Parts

Swashplate Parts

Shaft/Housing Parts

1. Inspect end cover for erosion, cracks, and burrs.

Clean up minor burrs with an India stone. If erosion or cracks are found, replace the end cover.

2. Inspect roller bearing and bearing race for nicks and pitting. Make sure the roller bearing turns freely within the bearing race. If the roller bearing needs replacement, both the roller bearing and the bearing race must be replaced.

3. Inspect valve plate for erosion, excessive wear, heavy scratches, and cracks. If any of the above conditions are found, replace the valve plate.

4. Inspect control piston and maximum displacement screw for burrs, scratches and cracks. Clean up minor scratches with 500 grit paper. Remove burrs with an India stone. The control piston should move freely in the bore.

1. Inspect swashplate face for wear, roughness or scoring.

Check the swashplate hubs and bearing surfaces for wear and cracks. Replace if defective.

2. Inspect saddle bearing surfaces for wear, pitting, and smooth operation. Replace if necessary.

1. Inspect drive shaft for wear, stripped splines, and burrs.

Remove burrs with an India stone. Inspect the contact area of bearing and shaft seal). Replace the drive shaft if wear or scoring is greater than 0.005 T.I.R. (total indicator reading).

2. Inspect drive shaft bearing for roughness, pitting of rollers, and excessive end play. Replace, if defective.

If the bearing needs to be replaced, the bearing race also requires replacement.

3. Inspect housing mounting flange for nicks and burrs.

Remove minor nicks and burrs with an India stone.

Also check the housing for damaged or stripped threads. If any thread is damaged, replace the housing.

4. Check remaining pump parts for excessive wear, damaged threads, burrs, cracks and erosion. Replace any part that is in questionable condition.

EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014 17

Inspection, Repair and

Part Replacement

Shimming Process

Shafty Bearing Shim

Kit 9900961-000

Shimming Process

Installation Information

This skim kit is to replace the bearing spacer within the pump housing. If the housing, drive shaft, shaft bearings or end cover is replaced during servicing, the original bearing spacer can no longer be used to assure proper bearing set.

End Cover 4

Cap Screw 16

Front Bearing 9

Bearing Spacer 2

Rear Bearing 10

Shaft 1

Shim Kit 9900961-000 2

Housing 8

Shimming Procedures

1. Measure the thickness of the existing bearing spacer .

2. To obtain a starting point, stack shims to a few thousandth of an inch less than the measurement of existing bearing spacer . Then insert shims into the end cover in the same location as the removed bearing spacer .

3. Assemble the housing

(without interface 0-ring seals), shaft bearings, shaft and end cover. Install the end cover cap screws and torque to 114±11 Nm.

4. Using a dial indicator, measure drive shaft end play.

Target bearing set range is .0005" to .003" clearance (no preload). Add or remove shims to achieve proper bearing set. If no movement of the shaft is observed, shims will need to be removed and steps 3 and 4 repeated.

5. Finish the assembly of the pump.

18 EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014

Assembly

1. Install Snap Ring and Shaft Seal 2. Insert the Shaft Bearing Race

3. Install Cradle Bearings 4. Install Cradle Bearing Screws

Note: The cradle bearings are asymmetrical. Install as shown in picture.

5. Install Bearing

Note: The old cap screws cannot be reused and must be replaced with new ones because the screws will be damaged during disassembly. The new cap screw threads will be coated with loctite. (2) bearings item 11 and (2) screws item 12.

6. Install Bias Spring

7. Install Swashplate 8. Install Control Piston

Note: With the bias spring in place, tilt the swash plate toward the spring and install the swash plate.

EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014 19

Assembly

9. Install Swashplate Retainer

11. Install Shaft

10. Install Swashplate Locator

Note: Adjust the screw until the swashplate is near neutral (will look flat in housing).

12. Install Shaft Retainer Tool

Caution: Use care while inserting shaft end through shaft seal.

13. Install the Rotating Group 14. Remove Swashplate Locator

15. Remove Swashplate Retainer 16. Install O-ring Seal

20 EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014

Assembly

17. Install Housing O-rings 18. Install Bearing Race into End Cover

19. Install Valve Plate 20. Install Bearing onto Shaft

Locating Pin

Note: Lightly coat the back plate side of the valve plate with petroleum jelly for retention during assembly. Install the valve plate over the bearing race aligning the small slot on the outside of the valve plate with the roll pin in the end cover.

21. Install End Cover 22. Install Compensator

Note: Ensure correct orientation. Use caution so valve plate does not fall off.

23. Testing

Perform functional test on pump according to Eaton test procedure. Contact your area sales manager for more information.

EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014 21

Assembly Torque Values

Instructions

Adjustable Maximum Stop

Option

Assembly Torque Values -

Instructions

Feedback Sensor Option

22 EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014

Notes

EATON 220 Piston Pump Service Manual E-PUMC-RR001-E2 February 2014 23

Eaton

Hydraulics Group USA

14615 Lone Oak Road

Eden Prairie, MN 55344

USA

Tel: 952-937-9800

Fax: 952-294-7722 www.eaton.com/hydraulics

Eaton

Hydraulics Group Europe

Route de la Longeraie 7

1110 Morges

Switzerland

Tel: +41 (0) 21 811 4600

Fax: +41 (0) 21 811 4601

Eaton

Hydraulics Group Asia Pacific

Eaton Building

No.7 Lane 280 Linhong Road

Changning District, Shanghai

200335 China

Tel: (+86 21) 5200 0099

Fax: (+86 21) 2230 7240

© 2014 Eaton

All Rights Reserved

Printed in USA

Document No. E-PUMC-RR001-E2

February 2014

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